Concept to Commissioning

High Speed Robotic Spot Welding Line


Customer Requirement

  • Completely automatic robotic spot-welding and handling line
  • Need to increase production from 300 vehicles/day to 2500 vehicles per day
  • Allowable breakdown time less than 0.01% of production time
  • Integration of 11 ABB robots
  • Between 30-50 spot welds per robot
  • Accurate fixtures and positioning tools
  • Factory Acceptance Test (FAT) before Dispatch
  • Ease of use and easy for maintenance.
  • Documentation for operator use, preventive maintenance and spares

Cybernetik Solution

  • Human assistive jig fixturing and positioning.
  • Optimized robotic spot welding programs for all robots
  • Performed simulations for entire system to prove feasibility before manufacturing.
  • Poka yoke at all locations
  • Complete System Integration
  • Safety systems to ensure operator safety
  • High speed pneumatic rotary indexers to optimize the cycle time and space for heavy jig payload
  • Optimized integration between robotic operations and jig movement operations to meet production rates
  • Documentation including operator/maintenance manual, preventive maintenance document, critical and recommended spares list

scope of project Scope

  • Installation and programming of 11 ABB robots with spot welding end of arm tooling
  • Rotary indexers for rotating the jig payload of 2 tons in 8 seconds
  • Integration over DeviceNet for robots and CC-link for jig handling
  • 11 station pallet line using rack and pinion indexers
  • Overhead pick and place systems for removing jig from the pallet line.
  • Easy to use SCADA and HMI systems

cost of project Cost

Under 500 thousand USD

schedule of project Schedule

6 months

Systems Offered by Cybernetik

Robotic welding systems
Skid transfer systems

Services Offered by Cybernetik View All

Concept generation

Feasibility study

Detailed engineering

Simulation using Virtual reality to prove final cycle times

Manufacturing, integration and testing

Installation and commissioning

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